US6334978B1 - Cast alloys - Google Patents

Cast alloys Download PDF

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Publication number
US6334978B1
US6334978B1 US09/351,841 US35184199A US6334978B1 US 6334978 B1 US6334978 B1 US 6334978B1 US 35184199 A US35184199 A US 35184199A US 6334978 B1 US6334978 B1 US 6334978B1
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United States
Prior art keywords
ingots
ingot
strontium
casting
group
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Expired - Fee Related
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US09/351,841
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English (en)
Inventor
David H. DeYoung
Mark J. Dunlay
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Alcoa Corp
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Alcoa Corp
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Priority to US09/351,841 priority Critical patent/US6334978B1/en
Assigned to ALCOA INC. reassignment ALCOA INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DEYOUNG, DAVID H., DUNLAY, MARK J.
Priority to CA002313541A priority patent/CA2313541A1/en
Priority to EP00114800A priority patent/EP1069195B1/en
Priority to ES00114800T priority patent/ES2208191T3/es
Priority to DE60005610T priority patent/DE60005610T2/de
Priority to AT00114800T priority patent/ATE251230T1/de
Priority to JP2000213065A priority patent/JP2001064743A/ja
Publication of US6334978B1 publication Critical patent/US6334978B1/en
Application granted granted Critical
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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C21/00—Alloys based on aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C

Definitions

  • the present invention is directed to the improvement in the casting of aluminum and aluminum alloys and the products made therefrom by the addition of small quantities of strontium and/or alkaline earth, rare earth, and/or transition metal combinations.
  • Alloys aluminum and aluminum alloys
  • imperfections in the casting of Alloys that can not be cured by cosmetic fixes. Some imperfections cause the cast piece to crack before it is worked. These are called various things by those skilled in the art and different companies have developed their own names for these imperfections. Such imperfections can include but are not limited to vertical folds, folds, pits, oxide patches, oxides or oxide clusters that become embedded in the surface in a solid ingot.
  • a vertical fold is a V-shaped indentation in the surface of a rolling ingot that is oriented in the longitudinal direction of the ingot. Some vertical folds initiate cracking of the ingot. A cracked ingot needs to be re-melted and re-cast since such an ingot can not be further processed or sold to a downstream customer.
  • Re-melting and Re-casting ingots is not only inconvenient but is also costly thereby reducing the efficiency of an Alloy mill. Most if not all ingots are worked in some manner, however, working will not heal a cracked ingot. Other surface imperfections may also serve as crack initiators. As is clear from the above, surface imperfections in ingots remain a problem in the Alloy art.
  • Working as that term has become known in the Alloy industry, can mean a lot of different things such as but not limited to hot rolling, cold rolling, extruding, forgiving, drawing, ironing, heat treating, aging, forming, and stretching to name a few.
  • energy is put into the workpiece but it is not always homogeneously distributed.
  • Alloys may be promoted by any number of methods known to those skilled in the art.
  • casting techniques are direct chill (“DC”), electromagnetic (“EMC”), horizontal direct chill (“HDC”), FDC casting, hot top casting, continuous casting, semi-continuous casting, die casting, roll casting, and sand casting.
  • DC direct chill
  • EMC electromagnetic
  • HDC horizontal direct chill
  • FDC casting hot top casting
  • continuous casting semi-continuous casting
  • die casting die casting
  • roll casting roll casting
  • sand casting sand casting.
  • Alloys may comprise any of the Aluminum Association Registered Alloys such as the 1xxx, 2xxx, 3xxx, 4xxx, 5xxx, 6xxx, 7xxx, and 8xxx series alloys.
  • the present invention would also be very useful for any of the foundry alloys.
  • the present invention is found particularly useful for the 2xxx, 3xxx, 5xxx, 6xxx, and 7xxx series alloys.
  • the addition of strontium and mixtures of strontium, the other alkaline earth metals, the rare earth series of elements and the transition elements it is found advantageous to add small quantities, no greater than 0.5 weight per cent in Alloys such as 2024, 2524, 3004, 5042, 5083, 5182, 6013, 6063, 7075, 7x55, and 7x50, to name a few.
  • the additions hereof to Alloys is helpful after the Alloys are worked whether the Alloys are worked whether the Alloys are worked whether the Alloys are foil, sheet, stock plate, that is plate thicker than half an inch upwards to about 8 inches or more, aircraft skin, can body stock, end stock, and/or extrusions. It is found that the small additions made to the ingot also have other appearance enhancing effects that survive in a worked piece if the cast surface is not removed from the metal before working.
  • U.S. Pat. No. 5,469,911 addressed the surface quality issue in EM casting with the addition of small amounts of calcium to the alloy that was added prior to the ingot head.
  • U.S. Pat. No. 4,377,425 addresses problems in DC casting through the use of similar amounts of calcium. Both claim to provide a surface free of many surface imperfections commonly associated with casting ingots but neither claim to be effective for a broad range of casting techniques. It is this across the board improvement in casting techniques that confounds the prior art.
  • the invention hereof has surprisingly shown that small amounts of strontium in Alloys can not only eliminate many surface imperfections, especially vertical folds, and pits but also enhances the reflectance of the Alloys. Additions of strontium and combinations are also found to reduce the oxidation of molten Alloys. Eliminating surface imperfections and reducing oxidation will increase product recovery at various process steps and thereby reduce production costs and increase the output of the production facility. Reducing oxidation will reduce losses of metal during melting, holding, and casting. This is known as melt loss.
  • the invention is found to be useful in the canning and other container structures, transportation such as airplanes, trains, boats, and cars, as appearance of the metal may be found advantageous to the consuming public.
  • the present invention is directed to the addition of small amounts of strontium and optionally up to about 0.25 weight percent grain refiners, the remaining alkaline earth metals, transition metals, and/or rare earth metals in combination with aluminum and aluminum alloys as a melt in order to improve the appearance and/or substantially eliminate surface imperfections and/or reduce surface oxidation in cast ingot aluminum and aluminum alloys.
  • the addition of the small amounts of these additives were found to surprisingly substantially eliminate vertical folds, pits and ingot cracking in more than one casting technique.
  • the additions also improved the appearance of the ingots, including reflectance. As a result the ingots could be reduced or worked essentially right out of the casting without first conditioning the surface by, for example, scalping.
  • the additions reduced the depth of lapping on DC cast ingots.
  • the amount of strontium added can be as much as 0.50, 0.40, 0.30, 0.29, 0.25, or 0.15 weight percent but can be as little as 0.0001 weight per cent when combined with other metals and/or grain refiners.
  • the range of strontium addition includes but is not limited to 0.001 weight per cent increments, such as 0.0011, 0.0012, 0.0013 etc. and includes but is not limited to incremental increases of 0.01 and 0.1 weight per cent.
  • strontium and alkaline earth elements such as magnesium, calcium, barium, or beryllium can be found to be useful as are additions of the rare earth metals such as holmium, cerium, erbium, lanthanum, and the other lanthanide and rare earth series of elements and some combination thereof, as well as small combinations of strontium and the transition metals such as titanium, scandium, and silver. It is found when combining strontium with the other aforementioned metals that it is preferred that the strontium combined additives have more strontium than the other mixed component metal. For example, it is preferred that strontium be present by at least more than 50% of what is being added. While this is preferred, smaller amounts of added strontium provide an operable improvement.
  • a surprising and significant part of the discovery of this invention is the reduction in the required depth of scalping.
  • scalping of the ingot is required from a depth of 0.3 to 0.7 inches (0.76 to 1.8 mm).
  • some measuring means such as with a laser, may be used to measure the lowest point on the ingot surface.
  • this is the v-notch, which is the point, generally in the middle of the ingot where the ingot was not well formed.
  • formation of the v-notch is inhibited and/or is essentially removed from the ingot face. Consequently, the scalped layer is substantially smaller.
  • the scalped layer now is less than 0.3, 0.2, 0.1 inches or eliminated altogether.
  • the need for scalping is further lessened to improve the surface of the ingot faces.
  • FIG. 1 is a picture of a DC cast ingot 5083 aluminum alloy without an additive change.
  • FIG. 2 is a picture of the same DC cast ingot 5083 aluminum alloy with the addition of 0.0023 weight per cent strontium.
  • FIG. 3 is a picture of a DC cast ingot 7050 aluminum alloy without an additive change.
  • FIG. 4 is a picture of the same DC cast ingot 7050 aluminum alloy with the addition of 0.027 weight per cent strontium.
  • Strontium was added to a 5083 series alloy during DC casting.
  • no addition was made in one cast and a strontium addition was made in four casts.
  • Ingots of cross section 16 inches by 60 inches were vertically cast by the direct chill method or DC casting. The ingots were cast at a speed of 2 inches per minute and were typically cast to a length of 180 inches.
  • Molten aluminum alloy flowed from a holding furnace through a trough and into a single stage in-line degassing unit known as the A622 process. Next, the alloy was flowed through a 30 pore per inch ceramic foam filter.
  • the final step in casting flowed the molten alloy through a spout and into the ingot mold.
  • no strontium was added to the metal, while in four other casts strontium was continuously fed into the degassing unit during the cast and thereby into the molten metal.
  • the strontium is mixed in rod form comprising 15 weight per cent strontium and 85 weight per cent aluminum.
  • the rod containing the 15 wt % strontium was fed into the molten aluminum alloy stream at a rate of 4, 8, 23, and 46 inches per minute.
  • the nominal addition levels resulted in these four casts comprising 0.0035 wt %, 0.0070 wt %, 0.0200 wt %, and 0.0400 wt % strontium in the aluminum alloy.
  • Table 1 summarizes the ingots that were produced during these casts and provides a qualitative assessment of the ingot surface appearance.
  • the alloy cast was alloy 5083 as defined by the Aluminum Association designation.
  • the addition of very small amounts of strontium to the 5083 alloy have dramatic effects on inhibiting the formation of folds and thereby decreasing the risk of ingot cracking.
  • the surface of ingots with strontium added were greatly improved as can be seen in the comparison of FIG. 1 and FIG. 2 .
  • FIG. 1 contains no strontium and exhibits many deep folds along the longitudinal axis. When the FIG. 1 ingot surface is compared with the FIG. 2 ingot surface the dramatic difference is evident at once.
  • FIG. 2 is the same 5083 alloy as FIG. 1 except that strontium is present in the FIG. 2 ingot.
  • a second series of test castings were cast using the 5042 alloy and the EMC casting method. Casts were made with and without strontium. The amount of strontium levels in this series were 0.0035 wt %, 0.0150 wt %, 0.0200 wt %, and 0.0400 wt % strontium. Molten 5042 alloy was treated in single stage in-line degassing unit and a packed bed filter. Table 2 provides a summary of this series of test casts.
  • a third series of test casts were cast using the 7050 alloy.
  • the ingots were produced using the DC casting technique. In these casts, the molten alloy was treated with a single stage degassing unit and flowed through a ceramic molten metal filter. Several casts were made without any strontium addition. The ingots exhibited small, deep folds or pits on the surface and both ingots cracked during casting as a result of the pits and folds.
  • a cast of the same 7050 alloy was made whereby strontium was continuously added in the form of a rod of 15 wt % strontium, the remainder aluminum. The nominal wt % of strontium in the ingot was 0.022.
  • FIG. 3 shows the cracks on the surface of the ingot without any strontium added.
  • FIG. 4 shows the absence of cracks and pits for the 7050 ingot with strontium additions. It is clear that strontium has a dramatic effect on the surface of the as cast ingots when added in small amounts.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)
  • Continuous Casting (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Physical Vapour Deposition (AREA)
US09/351,841 1999-07-13 1999-07-13 Cast alloys Expired - Fee Related US6334978B1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
US09/351,841 US6334978B1 (en) 1999-07-13 1999-07-13 Cast alloys
CA002313541A CA2313541A1 (en) 1999-07-13 2000-07-06 Improved cast alloys
DE60005610T DE60005610T2 (de) 1999-07-13 2000-07-10 Verbesserte Gusslegierungen
ES00114800T ES2208191T3 (es) 1999-07-13 2000-07-10 Aleaciones fundidas mejoradas.
EP00114800A EP1069195B1 (en) 1999-07-13 2000-07-10 Improved cast alloys
AT00114800T ATE251230T1 (de) 1999-07-13 2000-07-10 Verbesserte gusslegierungen
JP2000213065A JP2001064743A (ja) 1999-07-13 2000-07-13 改良された鋳造合金

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Application Number Priority Date Filing Date Title
US09/351,841 US6334978B1 (en) 1999-07-13 1999-07-13 Cast alloys

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US6334978B1 true US6334978B1 (en) 2002-01-01

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US (1) US6334978B1 (enrdf_load_stackoverflow)
EP (1) EP1069195B1 (enrdf_load_stackoverflow)
JP (1) JP2001064743A (enrdf_load_stackoverflow)
AT (1) ATE251230T1 (enrdf_load_stackoverflow)
CA (1) CA2313541A1 (enrdf_load_stackoverflow)
DE (1) DE60005610T2 (enrdf_load_stackoverflow)
ES (1) ES2208191T3 (enrdf_load_stackoverflow)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060089269A1 (en) * 2004-10-26 2006-04-27 John Bahaychick Lubricant for improved surface quality of cast aluminum and method
US20060089267A1 (en) * 2004-10-26 2006-04-27 Richter Ray T Lubricant for improved surface quality of cast aluminum and method
US20060089268A1 (en) * 2004-10-26 2006-04-27 Stewart Patricia A Lubricant for improved surface quality of cast aluminum and method
US20080263851A1 (en) * 2004-12-27 2008-10-30 Gyan Jha Shaped direct chill aluminum ingot
US20090000346A1 (en) * 2004-12-27 2009-01-01 Gyan Jha Shaped direct chill aluminum ingot
CN103014452A (zh) * 2012-12-27 2013-04-03 亚洲铝业（中国）有限公司 5182铝合金拉环料基材及其生产方法
US9096915B2 (en) 2009-01-06 2015-08-04 Nippon Light Metal Company, Ltd. Method of production of aluminum alloy
CN107338376A (zh) * 2017-07-11 2017-11-10 中铝瑞闽股份有限公司 一种铝合金车厢用板材的制备方法

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DE502004003603D1 (de) * 2004-03-11 2007-06-06 Geesthacht Gkss Forschung Verfahren zur Herstellung von Profilen aus Magnesiumwerkstoff mittels Strangpressen
DE102004022817A1 (de) * 2004-05-08 2005-12-01 Erbslöh Ag Dekorativ anodisierbare, gut verformbare, mechanisch hoch belastbare Aluminiumlegierung, Verfahren zu deren Herstellung und Aluminiumprodukt aus dieser Legierung
AT501867B1 (de) * 2005-05-19 2009-07-15 Aluminium Lend Gmbh & Co Kg Aluminiumlegierung
US20080299001A1 (en) * 2007-05-31 2008-12-04 Alcan International Limited Aluminum alloy formulations for reduced hot tear susceptibility
CN104690236A (zh) * 2013-12-10 2015-06-10 陕西宏远航空锻造有限责任公司 一种控制耐热钢晶粒度的生产方法
KR102591353B1 (ko) * 2016-09-29 2023-10-20 삼성전자주식회사 다이캐스팅용 알루미늄 합금 및 그 제조 방법
CN108160959B (zh) * 2017-12-28 2019-10-18 西南铝业（集团）有限责任公司 一种5182铝合金扁锭的铸造方法
CN114277271B (zh) * 2021-12-27 2022-09-30 连云港星耀材料科技有限公司 高强度复合改性铝合金制件及其制备方法
CN114293044B (zh) * 2021-12-30 2023-04-14 上海耀鸿科技股份有限公司 高塑性复合改性铝合金制件及其制备方法

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US4929511A (en) * 1983-12-06 1990-05-29 Allied-Signal Inc. Low temperature aluminum based brazing alloys
SU928823A1 (ru) * 1980-08-08 1996-02-20 А.В. Вахобов Сплав на основе алюминия
US5571347A (en) * 1994-04-07 1996-11-05 Northwest Aluminum Company High strength MG-SI type aluminum alloy
US5582659A (en) * 1993-10-12 1996-12-10 Nippon Light Metal Co., Ltd. Aluminum alloy for forging, process for casting the same and process for heat treating the same

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SU928823A1 (ru) * 1980-08-08 1996-02-20 А.В. Вахобов Сплав на основе алюминия
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US4929511A (en) * 1983-12-06 1990-05-29 Allied-Signal Inc. Low temperature aluminum based brazing alloys
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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060089269A1 (en) * 2004-10-26 2006-04-27 John Bahaychick Lubricant for improved surface quality of cast aluminum and method
US20060089267A1 (en) * 2004-10-26 2006-04-27 Richter Ray T Lubricant for improved surface quality of cast aluminum and method
US20060089268A1 (en) * 2004-10-26 2006-04-27 Stewart Patricia A Lubricant for improved surface quality of cast aluminum and method
US7111665B2 (en) 2004-10-26 2006-09-26 Alcon Inc. Lubricant for improved surface quality of cast aluminum and method
US7143812B2 (en) 2004-10-26 2006-12-05 Alcoa Inc. Lubricant for improved surface quality of cast aluminum and method
US7273086B2 (en) 2004-10-26 2007-09-25 Alcoa Inc. Lubricant for improved surface quality of cast aluminum and method
US20080263851A1 (en) * 2004-12-27 2008-10-30 Gyan Jha Shaped direct chill aluminum ingot
US20080295921A1 (en) * 2004-12-27 2008-12-04 Gyan Jha Shaped direct chill aluminum ingot
US20090000346A1 (en) * 2004-12-27 2009-01-01 Gyan Jha Shaped direct chill aluminum ingot
US8381384B2 (en) 2004-12-27 2013-02-26 Tri-Arrows Aluminum Inc. Shaped direct chill aluminum ingot
US8381385B2 (en) 2004-12-27 2013-02-26 Tri-Arrows Aluminum Inc. Shaped direct chill aluminum ingot
US9023484B2 (en) 2004-12-27 2015-05-05 Tri-Arrows Aluminum Inc. Shaped direct chill aluminum ingot
US9096915B2 (en) 2009-01-06 2015-08-04 Nippon Light Metal Company, Ltd. Method of production of aluminum alloy
CN103014452A (zh) * 2012-12-27 2013-04-03 亚洲铝业（中国）有限公司 5182铝合金拉环料基材及其生产方法
CN107338376A (zh) * 2017-07-11 2017-11-10 中铝瑞闽股份有限公司 一种铝合金车厢用板材的制备方法

Also Published As

Publication number Publication date
DE60005610D1 (de) 2003-11-06
DE60005610T2 (de) 2004-08-05
EP1069195A2 (en) 2001-01-17
EP1069195A3 (en) 2001-10-24
EP1069195B1 (en) 2003-10-01
ES2208191T3 (es) 2004-06-16
JP2001064743A (ja) 2001-03-13
ATE251230T1 (de) 2003-10-15
CA2313541A1 (en) 2001-01-13

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